Forklift-Rack Collision Classification for Fewer False Alarms
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Solution Overview
Problem
Existing collision monitoring systems in racking systems generate false alarms due to a single predetermined limit for all collision types, leading to operational disruptions, and battery-powered systems require frequent maintenance.
Innovation Solution
A method and system that classify collision events by combining sensor data from the racking system with state data from the forklift truck, using a sensor unit to detect collisions, determine their strength, and a control unit to classify them based on a collision type list, reducing energy consumption and maintaining battery life while minimizing false alarms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single predetermined limit is used for all collision types, then the collision monitoring system can be operated, but false alarms occur and operational disruptions result
Solution Approach 1:
The patent applies parameter changes by using multiple collision limits corresponding to different collision types (e.g., different g-force thresholds for different rack components). Instead of a single predetermined limit, the system adjusts the detection parameters based on the specific collision scenario, thereby reducing false alarms while maintaining operational continuity.
Solution Approach 2:
The system dynamically selects appropriate collision limits based on the detected collision characteristics. The control unit determines which collision type occurred and applies the corresponding limit from multiple predefined limits, making the system adaptive rather than static. This dynamic approach prevents false alarms while ensuring reliable detection.
2Use of energy by moving object
If battery-powered collision warning systems are used, then energy consumption is reduced, but frequent battery replacement and maintenance are required
Solution Approach 1:
The patent implements self-service by enabling the forklift's own energy resources (battery and power system) to serve the collision detection system. The forklift's control unit processes collision data and performs classification using the forklift's existing computational resources, eliminating the need for a separate battery-powered monitoring system on the rack and its associated maintenance requirements.
3Measurement precision
If complex collision analysis is performed on the racking system, then collision classification accuracy improves, but energy consumption and device complexity increase
Solution Approach 1:
The patent uses the forklift as an intermediary carrier for complex collision analysis. Instead of performing complex computations on the rack system, the collision data is transmitted to the forklift, which has sufficient computational resources. The forklift's control unit performs the detailed collision classification using state data and multiple collision limits, achieving high measurement precision without increasing the energy consumption or device complexity of the racking system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides reliable and precise collision event classification with minimal maintenance, enabling efficient resource management and accurate identification of collision types and locations, reducing operational disruptions and battery replacement frequency.
Implementation Method 1
The sensor unit is configured to measure a pulse transmission from the industrial truck to the racking system
Implementation Method 2
to detect a force, a g-force signal is generated by an accelerometer mounted on a material handling vehicle
Data Source
AI summary
The invention relates inter alia to a method for classifying a collision event (40) on a racking system (20), comprising the following steps: - a sensor unit (22) arranged on a racking system (20) detects a collision event (40) between a forklift truck (30) and the racking system (20) and determines a strength of the collision event (S110), compares the determined strength with a reference strength (S120) and sends out a collision signal (42) associated with the collision event (40) if the determined strength exceeds the reference strength (S130);- A receiving unit (34) of a forklift truck (30) receives the collision signal (42) and forwards it to a control unit (36) of the forklift truck (30) (S210), which performs a classification of the collision event (40) depending on state data of the forklift truck (30) and the collision signal (42) (S220), wherein the classification of the collision event (40) includes assigning a collision type from a collision type list, wherein the collision type list includes at least one collision type for which the collision event (40) is not assigned to the forklift truck (30), and at least one collision type, in particular at least two different collision types, for which the collision event (40) is assigned to the forklift truck (30).